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The Restoration of Valved High Frequency Communications Receivers

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The Restoration of Valved High Frequency Communications Receivers THE RESTORATION OF VALVED HIGH FREQUENCY COMMUNICATIONS RECEIVERS by: Chris Parry, G8JFJ Third Edition, January 2014 © Christopher Parry, 2014. This issue: 5th January 2014 You are welcome to freely distribute copies of this book provided it is kept complete, and with its copyright statement. If you wish to copy extracts from the text, or reproduce any of the pictures, then please attribute each extract and/or picture to Chris Parry, G8JFJ. This book is available free of charge as a service to the vintage radio community. If you have paid money for a copy of it, then someone has taken your money without the permission of the writer or the operator of the hosting server. The publicly available master copy of this book and its pictures are held only on Simon Buxton’s website www.vk2bv.org/radio/ Updated issues will be published on this site from time to time. PREFACE TO THIRD EDITION Several years have passed since this book was first published on Simon Buxton’s VK2BV website. The writer now realises he is lucky to have started in this hobby many years ago, long before the prices of old radios started to rise appreciably. In 2012, the supply of collectable and restorable old radios newly emerging from storerooms and garages all over the UK is finally drying up. Nevertheless there still seem to be many young people keen to learn the skill of working on this equipment. That is the good news for our hobby. Sadly, those who performed the original design and operational work are now elderly, and many are no longer able to teach the knowledge. Hopefully this book will help to plug the gap. Valves remain widely available but the emerging threat is forgeries, and some prices are rising out of control. The writer extends his most sincere thanks to VK2BV for publishing this book in its third edition. Table of Contents 1. Foreword and Acknowledgements 2. Scope 3. Abbreviations 4. Objectives 5. The Restoration Process 6. Supporting Information 7. Chassis and Mechanics 7.1 Chassis Cleaning 7.2 Earthing 7.3 Chassis Resoldering 7.4 Grommets 7.5 Gearboxes with Metal Gears 7.6 Gearboxes with Plastic Gears 7.7 String and Wire Dialdrives 7.8 Chain Drive 7.9 Friction Drive 7.10 Dialdrive Mechanics and Mountings 7.11 Gang Capacitors 7.12 Scaleplates 7.13 Optical Projection Systems and Filmstrip Scales 7.14 Screening and Insulation Structures 7.15 Cooling 7.16 Control Knobs 7.17 Printed Circuit Boards 7.18 Valve Sockets 7.19 Repair of Damaged Castings and Threads 7.19 Fully Sealed Radios 7.20 Bowden Cables 7.21 Special Paints & Finishes 7.22 Freeing Seized Screws 8. Switches, Turrets and Coilpacks 8.1 Rotary Wavechange Switches 8.2 Rotary IF Switches 8.3 Turrets 8.4 Interchangeable Coil Assemblies and Coilpacks 8.5 Slide Switches 8.6 Toggle Switches 8.7 Potentiometer Switches 9. Wound Components and Wiring 9.1 Initial Inspection 9.2 Screw Cores 9.3 Mains Arrangements 9.4 HT Insulation 9.5 Re-impregnation 9.6 Wiring and Looms 9.7 Motors 9.8 IFTs 9.9 Battery Wiring 9.10 Audio Transformers 9.11 RF Chokes 10. Thermionic and Other Active Components 10.1 Criteria for Selection of Valves 10.2 Valve End of Life Definition and Reliability 10.3 Valve Fabrication, Repair and Remanufacture 10.4 Loose Top Caps and Valve bases 10.5 Carbonizing and Metallized Coatings 10.6 Valvecans and Retainers 10.7 RF Amplifiers 10.8 Acorns and Nuvistors 10.9 Compactrons 10.10 Mixers 10.11 Local Oscillators 10.12 Automatic Frequency Control 10.13 Calibrators 10.14 IF Stages 10.15 Detectors and AGC 10.16 Magic Eyes 10.17 Noise Limiters 10.18 Audio Stages 10.19 HT Regulators 10.20 Thermionic Rectifiers 10.21 Transistor Stages 11. Passive Components 11.1 Wire-ended Component Replacement: General 11.2 Resistors 11.3 Non-electrolytic Capacitors 11.4 Electrolytic Capacitors 11.5 Barretters and Urdox Regulators 11.6 Bulbs 11.7 Trimmer Capacitors 11.8 Potentiometers 11.9 Crystals and Crystal Filters 11.10 Mechanical Filters 11.11 Thermistors 11.12 Non-thermionic Power Rectifiers 11.13 HT Vibrators 11.14 Non-thermionic Signal Diodes 11.15 Electromagnetic Relays 11.16 Thermal Time Delay Relays 11.17 Meter Movements 11.18 Headphone Sockets 11.19 Loudspeakers 12. Faultfinding and Realignment 12.1 Checks on First Power-up 12.2 Initial Running Checks 12.3 Alignment Prerequisites 12.4 Coilformer Core Positions 12.5 Double-tuned Transformers 12.6 Tracking the LO to the Dialplate 12.7 LO Frequency Jumping 12.8 Aligning the RF Stages, Mixer Grid and IF Trap 12.9 IF Response Problems 12.10 AGC Checks 12.11 Second Detector Issues 12.12 Noise Limiter Problems 12.13 Noise Blankers 12.14 IF Notch Arrangements 12.15 Crystal Oscillators 12.16 Ovens 12.17 BFO Injection 12.18 Intermittent Faults 12.19 Identifying and Curing Unwanted VHF Oscillation 12.20 The Audio 12.21 Post-alignment Tasks 13. Permeability Tuned Radios 13.1 Module Interdependency 13.2 Bristol Multiple Spline 13.3 Tuning Slugs 13.4 Mechanical Alignment 13.5 VFO Alignment 13.6 VFO Repairs 13.7 VFO and BFO Operating Shafts 13.8 VFO Types Other than Collins 13.9 PBT as Used in Collins Designs 13.10 Setting the IF Gain on Collins Designs 14. Performance Benchmarks 14.1 AGC Threshold 14.2 Noise Figure 14.3 Image Rejection 14.4 Third Order Intercept Point 14.5 1dB Compression Point 14.6 Mains Current 15. EMC Considerations 15.1 Emissions 15.2 Immunity 16. Some Interesting Equipment 16.1 Marine Radios: the RCA AR-8516L & Marconi Atalanta 16.2 Turrets: the Murphy B40D 16.3 Wafer Switches: the AME 7G1680BA 16.4 Restoration Techniques: the Marconi CR100/B28 16.5 Gearboxes: the Collins R-390 16.6 Permeability Tuning: the Collins R-390A 16.7 An Unusual Chassis Design: the RME Model 99 16.8 Catacomb Tuning Racks: the National NC100XA 16.9 The Best of the Wartime Sets: the RCA AR-88D 16.10 British Post-war AR-88 Equivalent: the GEC BRT400D 16.11 Rare and Complicated: the McMurdo DST100 16.12 Fire Hazard: the Hammarlund SP600JX-6 16.13 Styling: the Hallicrafters Super Skyrider SX28 16.14 Overkill for SSB: the Hoffman CV-157 16.15 Collectability: the Eddystone S940C 16.16 Heavily Screened: the Eddystone S880/2 16.17 British Coilpack Set: the Eddystone S358X/B34 16.18 Post-war Super Skyrider: the Hallicrafters SX62A 16.19 Last of the Line: the Drake R4C 16.20 The Most Famous Ham Receiver: the Collins 75A-4 16.21 A Competent HF Transceiver: the Collins KWM-2A 16.22 Wadley Loop Implementation: the Racal RA17L, RA117 & RA218 16.23 Early VHF: the Hallicrafters S36/BC-787-B 16.24 For the Avro Lancaster Bomber: the RAF R1155A 16.25 A Rare Prize: the PSEI Trophy-8 16.26 Ham Competitors: the Heathkit SB-300 and KW202 16.27 Complex British Ham Set: the Eddystone EA12 16.28 Early and Very Competent: the National HRO-MX 16.29 Very Late German Design: the Telefunken E127KW/4 16.30 Compact Post-war VHF: the Eddystone S770R/1 16.31 Mobile Military HF Receiver: the British Army R209 Mk2 16.32 Very Australian: the AWA CR-6A & CR-6B. 16.33 Better Than Expected: KW’s Last Gasp, the KW2000E. 17. Glossary 18. About the Writer 19. Photographs - taken with Canon Digital IXUS400 & IXUS95IS cameras [Pic001] Marconi CR100 mounted in a home constructed handling frame which protects the chassis in any position while it is receiving attention on the bench. [Pic002] PSEI Trophy-8 has paxolin valve sockets which cause earthing problems for the solder tags, as shown here on the RHS mounting screw sandwiched between the paxolin and the chassis - look carefully! [Pic003] GEC BRT400K showing a re-soldered chassis seam. Sprung joints are very common indeed on this model. [Pic004]N Drake R4C plastic gears, which feel very rough. The later metal gears work better, but are rare. [Pic005] Eddystone EA12 uses nylon dialdrive pulleys which swell over time due to water absorption. The result is excessive pointer travel from end to end. [Pic006] Marconi CR100 centrally captivated band change cord, which proved extremely difficult to replace. Look carefully to see how the cord enters the little metal drum in two places. It’s very difficult indeed to assemble it correctly. [Pic007] GEC BRT400K steel dialdrive wire runs in greased brass guides. Early variants (without front panel handles or dial lock) used pulleys. Dial lamps have been removed for clarity. [Pic008] British Army R209 Mk2 pressure testing set-up, showing the desiccator which has to be temporarily replaced by a purging bung for this operation. When all is well, the manometer shows unchanging pressure after initial pumping. [Pic009]N Hammarlund SP600JX-6 idler wheel & tensioner spring, a troublesome arrangement when the spring gets weak or if any oil gets onto the friction surfaces. [Pic010] National NC100XA dialdrive endstop plate shown standing vertically with one bevelled corner visible. This is a very poor design which required careful filing to operate correctly. [Pic011]N Collins R-390A Oldham coupler & tension spring, a very effective design which expedites dismantling and reduces the chance of muddling on reassembly. [Pic012] KW202 tuning capacitor, showing its non-standard glued plastic cover which considerably reduces VFO drift. Also shown is the Kokusai 455kHz SSB mechanical filter. [Pic013] Murphy B40D tuning gang, with its fragile ceramic shaft which snaps if the radio has been dropped.
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